Classification Status: Restricted

April, 2017 DOCUMENT NUMBER

BNL-CPP-ATP-01

OML58 MAJOR CIVIL WORKS AND RELATED INFRASTRUCTURE

CALL OFF CONTRACT

PROCEDURE FOR MARSHALL STABILITY, FLOW AND STIFFNESS OF

ASPHALT

BRIDGSITE NIGERIA LIMITED

The Process Owner for this plan is Project Manager

Revision Date Description Originator Checker Approver

R00 10-04-17 Issued for Internal review Trust .A. Akpan .F. Chilaka .U.

REVISION CHANGE DETAILS

Rev Location of Change Brief Description of Change

ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

TABLE OF CONTENTS

Contents

1 Reference.................................................................................................................................... 4
2 Scope.......................................................................................................................................... 4
3 Apparatus.................................................................................................................................... 4
4 Materials...................................................................................................................................... 7
5 Preparation.................................................................................................................................. 7
6 Testing of specimens................................................................................................................... 8
7 Calculations............................................................................................................................... 10
8 Reporting................................................................................................................................... 11
9 Notes on method........................................................................................................................ 11
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

Test Method: Stability, flow and stiffness of asphalt - Marshall

1 REFERENCE

This method is based on ASTM D6927-15: Standard Test Method for Marshall Stability and Flow of
Asphalt Mixtures.

2 SCOPE

This method sets out the procedure for preparing test specimens of freshly mixed asphalt (either
produced in the laboratory or at a mixing plant) by the Marshall procedure and determining stability,
flow and stiffness values of the specimens using the Marshall apparatus. It is applicable to asphalt
mixes not exceeding 28 mm nominal size.

3 APPARATUS

Where appropriate, the working tolerances of particular apparatus are contained in Tables 1, 2, 5
and Figure 1.

The following apparatus is required:

3.1 Specimen mould assembly, consisting of the following:

3.1.1 For asphalt of nominal mix size 20 mm, a cylindrical steel or brass
compaction mould having an internal diameter of 101.6 mm, a height of 89
mm and a thickness of 6 mm; a mould base with a thickness of 18 mm and an
extension collar having an internal diameter of 101.6 mm, a height of 70 mm
and a thickness of 6 mm.

3.1.2 For asphalt of nominal mix size > 20 mm, a cylindrical steel or brass
compaction mould having an internal diameter of 150.0 mm, a height of 89
mm and a thickness of 8 mm; a mould base with a thickness of 18 mm and an
extension collar having an internal diameter of 150.0 mm, a height of 70 mm
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

and a thickness of 8 mm.

3.2 Hand compaction hammer, consisting of the following:

3.2.1 For asphalt of nominal mix size 20 mm, a flat circular tamping face
having a diameter of 98.5 mm, and a sliding weight with a mass of 4.53 kg and
a free fall of 457 mm (Notes 9.1, 9.2 and 9.3).

3.2.2 For asphalt of nominal mix size > 20 mm, a flat circular tamping face
having a diameter of 149.0 mm, and a sliding weight with a mass of 9.92 kg
and a free fall of 460 mm (Notes 9.1,9.2 and 9.3).

3.3 Hand compaction pedestal, consisting of the following:

3.3.1 For asphalt of nominal mix size 20 mm, a wooden block, of

approximate dimensions 200 mm square and 450 mm thick, capped by a steel
plate of approximate dimensions 300 mm square and 25 mm thick. The air dry

density of the wooden block shall be 720 kg/m3. The plate shall be securely
attached to the block which shall be secured to a solid concrete floor or slab.
Suitable guides for restraining the compaction mould and locating the
compaction hammer centrally during compaction may be attached to the
block.

3.3.2 For asphalt of nominal mix size > 20 mm:

a) a wooden block as described in Step 3.3.1, or

b) a concrete block, of approximate dimensions 360 mm square
and 610 mm thick. Suitable guides for restraining the
compaction mould and locating the compaction hammer
centrally during compaction may be attached to the block.

3.4 Specimen extrusion jack, consisting of a hydraulic jack fitted with a plate on the ram and
located within a metal frame. The dimensions of the plate shall be 100 mm diameter and 6
mm thick for 101.6 mm test specimens, and 148 mm diameter and 12 mm thick for 150 mm
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

diameter test specimens. The frame shall retain the mould during extrusion of a test
specimen.

3.5 Breaking head, consisting of upper and lower cylindrical segments each having an
accurately machined inside cylinder face. The lower segment shall be mounted on a base
having two perpendicular guide pins extending upwards. Guide bushes on the upper
segment shall be located to direct the segments together without binding or loose motion on
the guide pins.

3.6 Marshall testing machine, gear driven at a constant speed to give a rate of travel on the
platen of 51 mm/min when the force is being applied, and capable of applying forces up to at
least 22 kN. The machine shall be fitted with one of the following measurement systems
(Note 9.4):

3.6.1 An elastic proving ring and two flow gauges. The proving ring shall be
inserted between the breaking head and the loading beam or crosshead to
measure the force on the test specimen. It shall have a capacity of at least 22
kN with a resolution of at least 0.002 mm and complying with a Class A device
for forces up to 4.5 kN and complying with a Class B device for forces
between 4.5 kN and its maximum loading. The flow gauges shall be placed on
the guide pins of the breaking head and shall be capable of measuring the
vertical deformation of the test specimen from the onset of load. The gauges
shall have a scale interval of no more than 0.1 mm.

3.6.2 A load cell and transducer and appropriate continuous recording device
of a capacity and accuracy at least equivalent to that of the proving ring and
flow gauges described in Step 3.6.1.

3.7 Water bath, mechanically agitated and maintained at a temperature of 60C. The bath
shall be at least 150 mm deep and shall be fitted with a perforated shelf about 50 mm from
the bottom.
3.8 Oven, thermostatically controlled at an operating temperature corresponding to the
appropriate compaction temperature specified in Table 3.
3.9 Hotplate, suitable for heating the mixing apparatus.
3.10 Balance of suitable capacity, with a resolution of at least 0.1 g and with a limit of
performance within the range of 0.5 g.
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

3.11 Thermometer, a partial immersion thermometer or other suitable temperature

measuring device having a temperature range which includes the appropriate range of Table
3, and graduated to 1C or less with an uncertainty of no more than 0.5C.
3.12 Measuring device, suitable for the measurement of the height of test specimens and
with a resolution not exceeding 1 mm.
3.13 Marker.
3.14 Mixing apparatus, such as steel tray, steel trowel, spatulas and scoop.

4 MATERIALS
The following materials are required:
4.1 Lubricant, suitable grease or viscous oil for lubricating the compaction moulds
(Note 9.5).
4.2 Paper segments, of sufficient size to cover the mould base.

5 PREPARATION
Perform the following for each test specimen to be prepared:
5.1 Bring the oven to an operating temperature corresponding to the compaction
temperature specified for the binder and asphalt type in Table 3.

5.2 Assemble the compaction mould (Note 9.6).

5.3 Place the compaction mould in the oven for approximately 1 hour.

5.4 Place the appropriate mixing apparatus on the hotplate.

5.5 Using the expected compacted density for the mix, calculate the required mass of the
mix for the compaction mould to give the desired specimen height of 63.5 mm (Note 9.7).

5.6 Prepare the mix in accordance with Subsection 4.2 of Test Method Q301.

5.7 Remove the compaction mould from the oven and position a paper segment on the
base within the mould.

5.8 Transfer the mix into the mould and level the surface of the mix, taking care to avoid
segregation.

5.9 Place the mould in the oven for 60 5 minutes.

5.10 Remove the mould from the oven and measure the mix temperature (Note 9.8).
Provided that the temperature of the mix is within the compaction temperature range
specified in Table 3, position a paper segment on the surface of the mix (Note 9.9).
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

5.11 Transfer the compaction mould to the compaction pedestal and compact the mix
using the specified number of blows of the compaction hammer at a rate of 60 to 70 blows
per minute with the hammer axis held vertically (Notes 9.2 and 9.10).

5.12 Remove the collar and base, and reassemble the compaction mould with the test
specimen inverted (Note 9.11).

5.13 Compact the mix further using the specified number of blows of the compaction
hammer at a rate of 60 to 70 blows per minute (Notes 9.2 and 9.10).

5.14 Remove the collar and base plate from the compaction mould and paper segments
from the test specimen (where relevant), and mark the face of the test specimen clearly with
an identification number (Note 9.12).

5.15 Allow the mould to cool in air and then extrude the test specimen.

6 TESTING OF SPECIMENS
6.1 Remove any lip formed around the edges of each test specimen without damage to
the test specimen.

6.2 Measure the height of each test specimen at four points evenly spaced around the
specimen and calculate the average height to the nearest 1 mm. Discard any test specimen
having an average height outside the range of 57 to 70 mm (Note 9.13).

6.3 Clean the inside surfaces of the breaking head and lightly grease the guide
pins.

6.4 Place the breaking head segments (where practicable) and test specimens in the
water bath for 30 to 40 minutes.

6.5 Remove the breaking head segments from the water bath (where relevant) and complete
Steps 6.6 and 6.7 within 30 seconds (Note 9.14).

6.6 Remove a test specimen from the water bath and place it centrally on its side
in the lower segment of the breaking head. Place the upper segment of the breaking
head on the test specimen and place the complete assembly centrally on the Marshall
testing machine.

6.7 Zero the measurement system, start the Marshall testing machine and perform
the test as follows:
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

6.7.1 For the proving ring and flow gauge system, apply the load until
shear failure causes the proving ring dial gauge reading to decrease.
Remove the flow gauges immediately from the breaking head and record
the dial gauge reading to the nearest division and the flow gauge readings
to the nearest 0.1 mm.

6.7.2 For the load cell and transducer system, where there is provision to
capture and review load cell and transducer readings at specific time
intervals, perform the following:

a) Apply the load and record load cell and transducer

readings at intervals of 0.01 s until shear failure causes the load
cell reading to decrease.

b) Determine the first four successive load cell readings where:

i. the range of the four readings does not exceed 0.1 kN,
or

ii. the range of the four readings exceeds 0.1 kN but

the fourth reading is lower than the first reading.

c) Record the first of these four successive readings as the test

load cell reading.

d) Determine the transducer reading corresponding to the test

load cell reading, adjust it for any seating error and record the
adjusted reading as the test transducer reading.

6.7.3 For the load cell and transducer system, where there is no
provision to capture and review load cell and transducer readings at
specific time intervals, apply the load until shear failure causes the load
cell reading to decrease. Record the load cell and transducer readings
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

corresponding to the maximum load cell reading (Note 9.15).

6.8 Repeat Steps 6.6 and 6.7 for each of the remaining test specimens.

7 CALCULATIONS

7.1 Stability

7.1.1 Calculate the load (L) applied to each test specimen at shear failure to
the nearest 0.1 Kn using as appropriate:

a) the recorded dial gauge reading and the calibration

relationship for the proving ring as determined in Step 6.7.1, or

b) the test load cell reading as determined in Step 6.7.2.

7.1.2 Calculate the stability of each test specimen to the nearest 0.1 kN as
follows:

S=LF

where S = stability of test specimen (kN)

L = load at shear failure (kN)
F = correction factor of Table 4 according to the height of
specimen
the test

7.1.3 Calculate the stability of the asphalt as the average of the test
specimen stability values to the nearest 0.1 kN.

7.2 Flow

7.2.1 Calculate the flow of each test specimen at shear failure to the nearest
0.1 mm using as appropriate:
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

a) the average of the two flow gauge readings recorded in Step

6.7.1, or
b) the test transducer reading as determined in Step 6.7.2.
7.2.2 Calculate the flow of the asphalt as the average of the test specimen
flow values to the nearest 0.1 mm.

7.3 Stiffness

Calculate the stiffness of the asphalt to the nearest 0.1 kN/mm as follows:

Stiffness = stability of the asphalt

flow of the asphalt

8 REPORTING

Report the following:

8.1 Stability to the nearest 0.1 kN.

8.2 Flow to the nearest 0.1 mm.

8.3 Stiffness to the nearest 0.1 kN/mm.

8.4 The number of blows applied to each face of the test specimens during compaction.

9 NOTES ON METHOD

9.1 Where a mechanical compactor is used instead of the hand compactor, the mass,
free fall and design of the hammer foot should be identical to those of the hand compaction
hammer and the automatic compactor should be securely anchored to a concrete base.

9.2 Where a mechanical compactor is used, it should be calibrated against hand

compaction to determine the number of blows equivalent to the specified number of blows of
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

hand compaction. Calibration checks should be performed on a regular basis and the difference
between the density results obtained using the mechanical and hand compaction method should
be no greater than 0.01 t/m3. Calibration should be conducted using quartered samples of the
mix.

9.3 To ensure free fall of the weight is maintained, the shaft of the hammer should be
thoroughly cleaned and dried after each set of compaction blows.

9.4 The apparatus described in Step 3.6.1 is unsuitable for testing stone mastic asphalt
and that described in Step 3.6.2 must be used for this purpose.

9.5 Before handling the lubricant, the operator must consult the relevant Safety Data
Sheet (SDS).

9.6 The cylinder, base and collar may be lightly greased prior to assembly to prevent
asphalt mix adhering to the mould.

9.7 For 101.6 and 150 mm diameter moulds, approximately 1250 and 2750 g respectively
are usually required.
9.8 For mixes susceptible to loss of binder by the draindown effect, for example, open
graded asphalt, the mix in the mould may be tipped out, then returned to the mould and
levelled to evenly distribute the binder, taking care to avoid segregation.

9.9 The paper segment may be lightly greased prior to placement on the mix to prevent
asphalt mix adhering to the compaction hammer.

9.10 Where the number of blows is not specified, 50 blows shall be used.

9.11 Where the paper segments have been lightly greased, they may be removed from the
test specimen.

9.12 For coarsely graded mixes, for example, open graded asphalt, removal of the base
plate may be delayed until the mould has cooled.
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

9.13 Any discarded test specimen should be replaced with an additional test specimen
prepared in accordance with Steps 5.1 to 6.2.

9.14 If Steps 6.6 and 6.7 are not completed within 30 seconds of removal from the water
bath and no load has been applied to the test specimen, the breaking head (where
practicable) and test specimen shall be returned to the water bath for at least 10 minutes and
Steps 6.5 to 6.7 shall be repeated. If the test specimen has been removed from the water
bath for more than five minutes, Steps 6.4 to 6.7 shall be repeated.

9.15 For some asphalt mix types, for example, stone mastic asphalt, the load cell reading
may not decrease after shear failure. In cases where the plotted curve plateaus or continues
to increase at a near constant rate following shear failure, the recorded load cell and
transducer readings shall correspond to the point where the curve generally attains its ultimate
constant slope. In this case, any seating error must be deducted from the transducer reading.

Table 1 Compaction equipment dimensions

Compaction equipment Mix nominal size

(mm)

20 > 20
Dimension Tolerance Dimension Tolerance
Compaction mould
Internal diameter of cylinder (mm) 101.6 0.2 150.0 0.2
Internal diameter of collar (mm) 101.6 0.2 150.0 0.2
Wall thickness (mm) 6 minimum 8 minimum
Compaction hammer
Mass of sliding weight (kg) 4.53 0.02 9.92 0.05
Free fall of sliding weight (mm) 457 1 460 3
Diameter of tamping face (mm) 98.5 0.1 149 0.2
Compaction pedestal
Wooden block, air dry density 720 50 720 50
(kg/m3)

Table 2 Test apparatus requirements

Apparatus Requirement Tolerance

Marshall testing machine
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

Rate of travel (mm/min) 51 3

Water bath
Temperature (C) 60 1
Oven
Temperature (C) Table 3 5

Table 3 Mix compaction temperatures

Binder Asphalt type Compaction temperature

(C)
Class 170 bitumen Dense graded 142 3
Class 170 bitumen Open graded 120 3
Class 320 bitumen Dense graded, stone mastic 150 3
Class 320 bitumen Open graded 125 3
Class 600 bitumen Dense graded 155 3
M1000/320 multigrade bitumen Dense graded 155 3
Polymer modified binder Dense graded, stone mastic 160 3
Polymer modified binder Open graded 140 3

Table 4 Factors for correcting Marshall stability for specimen height

Specimen Correction factor (F) Specimen Correction factor (F)

height height
101.6 mm 150 mm 101.6 mm 150 mm
(mm) (mm)
57 1.19 1.3 64 0.99 0.99
58 1.16 1.25 65 0.96 0.96
59 1.13 1.2 66 0.94 0.92
60 1.1 1.15 67 0.92 0.89
61 1.07 1.11 68 0.9 0.87
62 1.04 1.06 69 0.88 0.84
63 1.01 1.02 70 0.86 0.82
ITT: OML58 MAJOR CIVIL WORKS AND PROCEDURE FOR MARSHALL STABILITY,
RELATED INFRASTRUCTURE CALL OFF CONTRACTS FLOW AND STIFFNESS OF ASPHALT

Figure 1 Example of typical Marshall breaking head

Table 5 Breaking head dimensions (mm)

Mould A Typical dimensions

diameter
B C D E Segment
width
101.6 101.6 0.2 19 9.5 9.5 6.35 76
150 150.0 0.2 17.5 14.3 14.3 9.5 101.4